DuPont Automotive Performance Materials to Help Electrify Vehicles

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1 DuPont Automotive Performance Materials to Help Electrify Vehicles Hitoshi Shioya Paul J Kane Segment Leader - Asia Pacific North America

2 HV/EV market forecast Over 10% of Vehicle Production 2 CY2020 Estimated by HIEDGE 2009

3 Materials to Help Electrify Vehicles Requirements: Reduce mass Extra 200/kg mass of HEV components Temperature 40C to 170C Electrically Isolative Di-electric strength Di-electric constant Volume resistivity EMI shielding-hybrid materials Thermal Management Chemical Resistance (eg. LLC) Hydrolysis Resistance Thermally Conductive 3 Graphic source U.S. Department of Energy

4 HEV/EV Components 4 Electric Battery Pack Electric Motor/Generator Power Electronics ECU, Inverter, etc. High Voltage Connection Systems Thermal Management Systems Graphic source U.S. Department of Energy

5 Reduce 200kg in the 3 Major Systems 5 Inverter the hot spot Motor power control Battery s voltage step up DC/DC converter Battery keep it within operating temperature Energy storage Motor insulate better, boost efficiency Generator Power source Toyota Prius

6 Next Generation Inverter Challenge to Reduce Mass and Cost via Parts Integration 6 IGBT Lead frame Connectors/Cables High-Energy Cables and Connectors High temperature thermoplastic elastomer DuPont ETPV, Hytrel Power Control/Inverter Module Housings and Connectors High temperature PPA Over-mold Electrical Lead Frames Leak free paths for coolant (indirect coolant exposure to electronics)

7 Next Generation Battery Pack Challenge to Reduce Mass, Cost and Boost Performance 7 Frames and Structures Cell Separators Electrolyte, Electrodes and Binders Top temperature operating range of 40-60C still requires dimensionally stable LLC resistant materials for structures - Zytel HTN 54G35 HSLR is a prime candidate for exposure to moisture/coolant in battery thermal management system Higher temperature cell separator membranes are coming from DuPont better barrier properties and lower ionic resistance R&D effort on improved electrolyte, electrodes, binder materials

8 Next Generation Motors Challenge to Reduce Mass, Cost and Boost Performance 8 Magnet wire insulation Connectors and bus bars Rotor magnet encapsulation Connectors and encapsulations -high ATF resistance, low creep, USCAR Class 5 (170C) capability Zytel HTN (PPA) - best combination of ATF resistance and electrical properties Rectangular (flat) magnet wire calls for special insulating systems Proven insulating systems available for wire coatings, slot liner materials, etc.

9 DuPont Polymer Use In A Motor Example 9 Kapton (CR) Teflon Crastin (PBT) Vespel (PI) Vespel PI Nomex Voltatex Core Sheet Varnish Krytox Crastin (PBT) Teonex (PEN) Voltron TM Wire Enamel Voltatex Impregnating Resin Zytel HTN Zytel PA66 Zenite LCP Delrin (POM)

10 New Materials Driven by New Requirements Introducing a New Class of PPA Materials for High Voltage Connection Systems EF - PPA Electronic/Electrically Friendly Isolation Resistance Highest CTI 600 V Well balanced Mechanical Properties 10

11 New DuPont Zytel HTN Grades Combat Corrosion of Electrical Wire, Contacts 11

12 12 HTN51G35EF improves Electrical Performance HTN51G35EF : 2. % PPS : 1.6% HTN51G35EF : cm HTN51G35HSL: 10 9 cm HTN51G35EF : 600V PPS : 150V Spider charts compare HTN51G35EF with PPS

13 13 EF Meets High Voltage Needs Polymer Type PPA PPA PA66 PPS Trademark (DuPont) Zytel HTN51 (EF Grades**) Zytel HTN51 Zytel Glass Transition Temp, Tg (oc) Volume 150 oc E+11 1 E+9 1 E+6 1 E+13 Tracking Index, CTI 600V 600V 400V 150V Applications Structural, Electrical, High voltage Structural, Electrical Structural, Electrical ** EF = Electrical / Electronics Friendly Technology

14 14 High CTI is Crucial to Minimize Arcing Damage Resin PPA (HTN) - EF % GR PPS % GR PBT 450 CTI (volts)

15 Next Generation EV Thermal Management System Challenges of Space and Cost 15 Integrating cooling circuits to manage ICE, HVAC, high temperature electronics, cool and heat the battery Electrical Coolant Pumps, impellers, valves Thermostats Surge tanks Hose, tubing Electronic controls Imagine a multi-functional manifold to integrate and condense the entire system to feed and manage temperatures of each circuit individually

16 Improved Long Life Coolant Resistance 16

17 17 PPA Retains Properties in Hot Coolant 250 After Water/Glycol 130ºC Break (MPa) PPS-2 (40% Glass) PPA 35%GR PPS-2 (40% Glass) Time of Aging (h)

18 PPA Withstands Demanding EV Challenges 18 Polymer PA 66 PPA (HTN) PPA (HTN) PPS Glass Content 33% 35% 45% 40% Tensile Strength, MPa DAM 50% RH Elongation, % DAM 50% RH Tensile Modulus, MPa DAM 50% RH Notched Izod Impact, kj/m2 DAM 50% RH ,500 8, ,500 12, ,000 15, ,000 (Flexural) Specific Gravity Property Case for Using PPA in Demanding EV applications

19 PPA Maintains Rigidity, Strength at High Temperatures, critical for coolant tubes, channels 19 2,000 Flexural Modulus, kpsi 1,500 1, PA66 33% GR PPS 40% GR PPA (HTN) 35%GR Temperature, C

20 Polymer Solutions for Hybrid Vehicles High Voltage Connectors Zytel HTN EF (electrically friendly resin) Power Electronics Special DuPont polymers for over molded lead frames for power inverter DuPont solutions for indirect cooling of power electronics Li-ion Battery systems Zytel HTN for dimensional stability, coolant resistant for liquid cooled battery system Zytel EF resins for critical electronic over molding to monitor battery cells DuPont Flame Retardant Resins (UL-V0) Electric Motor and Generators Zytel HTN for permanent magnet retention 20

21 Materials to Reduce Friction Get Power to the Ground 21 Dave Ritchey Global Transportation Segment Leader, DuPont Vespel

22 22 Copyright 2009 DuPont. The DuPont Oval Logo, The miracles of science, DuPont, and all products named in this presentation are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates Because we cannot anticipate or control the many different conditions under which this information and/or products may be used, neither DuPont nor the authors guarantee the applicability or the accuracy of this information or the suitability of its products in any given situation. Users of DuPont products should make their own tests to determine the suitability of each product for their particular purposes. The data listed herein falls within the normal range of product properties but they should not be used to establish specification limits or used alone as the basis of design. Disclosure of this information is not a license to operate or recommendation to infringe a patent of DuPont or others. CAUTION: This product is not permitted to be sold for use in medical applications involving implantation in the human body or where contact with internal body fluids or tissues will equal or exceed 24 hours. For applications involving contact of less than 24 hours, see DuPont Medical Caution Statement, H or contact your DuPont sales representative.

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